Anti-spalling body armor protection system

ABSTRACT

An anti-spalling ballistic body armor device, usable in a vest or jacket form configured for being worn on a body, includes one or more plates made of ballistic metal material, the plate having a surface defining a strike surface for orientation away from a wearer&#39;s body in use, and having a spacing body and anti-spalling body and/or enclosure for preventing the spalling of bullets that hit the body armor device and thereby reduce bodily injury, the one or more plates also being configured with a flange portion to redirect bullet fragments away from the wearer&#39;s head and being further contoured by the formation of at least one bend in the plate.

CROSS-REFERENCE TO RELATED APPLICATION

This is a non-provisional application which claims priority to U.S. provisional application Ser. No. 62/079,271, filed Nov. 13, 2014, the contents of which are incorporated herein in its entirety.

TECHNICAL FIELD

This disclosure relates in general to wearable personal protection devices to protect a wearer from ballistic fire, such as from small arms fire, and relates in particular to a wearable ballistic protection system that has anti-spalling capabilities and which is configured for more comfortable wearability.

BACKGROUND OF THE DISCLOSURE

Wearable protection devices for protecting the wearer from bullets, small arms fire or shrapnel are known. Existing ballistic protection devices include coverings made of Kevlar or similar material. Other existing ballistic protection devices comprise ceramic or steel plates worn in a plate carrier vest of some type. Police officers, military personnel and other law enforcement personnel require ballistic protection to fulfill their duties. Even firefighters in some areas are required to wear ballistic protection.

Conventional Kevlar or similar type coverings can deteriorate over time due to changing environmental conditions and the entire protection package must be replaced. Frequent replacement is expensive and cumbersome. The replacement rate for currently designed Kevlar jackets is five to ten years.

Kevlar or similar material, also known as Soft Body Armor, without steel backing, localizes bullet impact energy and can contribute to blunt force trauma to the wearer's body in some instances.

Ceramic plates used in carrier vests also deteriorate. Ceramic is fragile and cannot withstand constant abuse. Dropping or bumping a ballistic jacket having ceramic plates can completely compromise the effectiveness of one or more of the ceramic plates by causing cracks or fissures in the ceramic material. Ceramic plates are also compromised with a single bullet impact and need immediate replacement. Ceramic plates cannot adequately protect a wearer from multiple bullet strikes. Further, due to the fragile nature of ceramic plates, x-ray or ultrasound testing is performed to assure non-failure of the ceramic plates, which is a costly procedure.

Existing carrier vests that include steel plates are bulky. The steel plates lay flat along the chest and back. The edges of the plates protrude away from the body, prohibiting full arm movement. Interference between the wearer's arms and the edges of the steel plate force the wearer to extend his elbows out away from the body, thereby limiting full range of motion and reducing the wearer's speed and flexibility.

When a bullet impacts a steel plate, spalling occurs and bullet fragments radiate uncontrollably, causing secondary damage to the wearer with potential injury to arms, legs, feet, throat, neck, head and face areas. Spalling also occurs when bullets strike Kevlar and similar material vests, and Kevlar vests with ceramic plates, which also causes injuries to the wearer's face, arms and other body areas.

Thus, it would be advantageous to provide a body protection system having anti-spalling properties, and that can be worn to overcome the problems associated with existing wearable body armor.

SUMMARY

In a first aspect, a body armor system for attachment to a wearer's upper torso comprises a front torso plate sized for positioning over a wearer's chest, the front torso plate having a forward facing surface for orientation away from the wearer's body, a top margin for orientation toward a wearer's head, a bottom margin in opposed position to the top margin and two side margins each extending between the top margin and the bottom margin, the front torso plate being configured with at least three bends to effect a contour of the front torso plate between the two side margins. This aspect of the disclosure is particularly suitable for resisting ballistic fire and resisting bullet spalling, while providing a body armor system that is more comfortable to wear.

In certain embodiments, the at least three bends further comprise a medial bend of the front torso plate, which extends upwardly from the bottom margin toward the top margin of the front torso plate, and two lateral bends, one each positioned on either side of the medial bend, each lateral bend extending upwardly from the bottom margin of the front torso plate.

In other certain embodiments, the top margin of the front torso plate is angled outwardly in a direction away from the forward facing surface.

In yet other embodiments, the body armor system further comprises at least two side armor plates, each side armor plate being sized for orientation along one of the two sides of the wearer's body and being oriented for positioning on either side of the front torso plate.

In certain embodiments, each of the two side armor plates is formed with at least one bend to provide a contoured shape of the side armor plates for enabling each side armor plate to curve along the sides of the wearer's body.

In some embodiments, the body armor system further comprises a rear torso plate sized for positioning over a wearer's back, the rear torso plate having an outward facing surface for orientation away from the wearer's body, a top margin for orientation toward a wearer's head, a bottom margin in opposed position to the top margin and two side margins each extending between the top margin and the bottom margin.

In certain other embodiments, the rear torso plate is further configured with at least three bends to effect a contour of the rear torso plate between the two side margins of the rear torso plate.

In yet other embodiments, the at least three bends further comprise a medial bend of the rear torso plate, which extends upwardly from the bottom margin toward the top margin of the rear torso plate, and two lateral bends, one each positioned on either side of the medial bend, each lateral bend extending upwardly from the bottom margin of the rear torso plate.

In certain other embodiments, the top margin of the rear torso plate is angled outwardly in a direction away from the outward facing surface of the rear torso plate.

In yet other embodiments, the body armor system further comprises two side armor plates, each positioned between the front torso plate and the rear torso plate and being oriented to be positioned along the sides of the wearer's body in use, each side armor plate being contoured to enable each side armor plate to curve about a side of the wearer's body in use.

In still other embodiments, the front torso plate, the rear torso plate and each side armor plate is each encased within a ballistic impact enclosure and each has a spacing body positioned between at least part of the plate and the ballistic impact enclosure.

In certain other embodiments, each of the front torso plate, rear torso plate and two side armor plates is formed with a strike face comprising a surface of the plate that is positioned for orientation away from a wearer's body, and the spacing body is positioned between the strike face of the said front torso plate, rear torso plate and side armor plates and the ballistic impact enclosure.

In other embodiments, each of the front torso plate, rear torso plate and two side armor plates, encased in the ballistic impact enclosure, is further positioned within a receiving pocket of an outer carrier vest or jacket that is configured for attachment to the upper torso of a wearer in use.

In still other embodiments, the front torso plate, rear torso plate and two side armor plates is each made of military ballistic steel.

In yet other embodiments, the ballistic impact enclosures are made of material having antiballistic property.

In certain other embodiments, the spacing body is made of flexible, impact resilient material.

In a second aspect, a ballistic protection device for use in a body armor device, vest or jacket configured for being worn on a body comprises a plate made of ballistic metal material, the plate having a surface defining a strike surface for orientation away from a wearer's body and being contoured by the formation of at least one bend in the plate, an enclosure encasing the plate, the enclosure being made of material having antiballistic properties, and spacing material positioned between the plate and the enclosure at least along the strike surface of the plate. The ballistic protection device provides advantages over known devices in providing a contoured metal armor plate with construction that provides anti-spalling properties and improved wearability.

In some embodiments, the spacing material is secured to the strike surface of the plate.

In certain other embodiments, the spacing material is secured to an inside surface of the enclosure to position the spacing material adjacent the strike surface of the plate.

In a third aspect of the disclosure, an anti-spalling body armor device comprises at least one steel plate having a top margin, a bottom margin and side margins extending between the top margin and the bottom margin, and having an outwardly facing surface oriented, in use, away from a wearer's body, the outwardly facing surface defining a strike face; a spacing body positioned adjacent the strike face of the at least one steel plate; an anti-spalling body positioned adjacent the spacing body; and a metal encasement positioned to encase the spacing body and the anti-spalling body against the at least one steel plate, the metal encasement being secured to the at least one steel plate in sealing arrangement therewithin.

In some embodiments, the anti-spalling body armor device further includes an anti-ballistic enclosure sized to receive and enclose the assemblage of the at least one steel plate, spacing body, anti-spalling body and metal encasement therein.

In certain embodiments, the anti-spalling body comprises a plurality of layers of woven material having anti-ballistic properties.

In certain other embodiments, the at least one steel plate further comprises a flange portion positioned along the top margin, the flange portion extending outwardly from the outwardly facing surface.

In other embodiments, the body armor device further includes a carrier vest having at a pocket configured to receive the assemblage of the at least one steel plate, spacing body, anti-spalling body and metal encasement within.

In still other embodiments, the at least one steel plate is formed with at least one bend extending upwardly from the bottom margin toward the top margin.

Other aspects, features, and advantages will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, which are a part of this disclosure and which illustrate, by way of example, principles of the inventions disclosed.

DESCRIPTION OF THE FIGURES

The accompanying drawings facilitate an understanding of the various embodiments.

FIG. 1 depicts one example of a type of carrier device or jacket that may be used in carrying out the body armor protection system in accordance with this disclosure;

FIG. 2 is a front view in elevation of a front torso plate in accordance with a first aspect of the disclosure;

FIG. 3 is a perspective view of the front torso plate shown in FIG. 2;

FIG. 4 is a bottom view of the front torso plate shown in FIG. 3, taken at line 4-4;

FIG. 5 is a perspective view of an alternative embodiment of a front torso plate in accordance with the disclosure;

FIG. 6 is a perspective view of a side armor plate in accordance with the disclosure;

FIG. 7 is a bottom view of the side armor plate shown in FIG. 6, taken at line 7-7;

FIG. 8 is a view of a front torso plate, in partial cut-away, and partial view of a carrier jacket, depicting the construction of an enveloped front torso plate and illustrating the insertion of the front torso plate into a carrier;

FIG. 9 is a partial view in cross section of the enveloped front torso plate shown in FIG. 8, taken at line 9-9;

FIG. 10 is a partial view in cross section of an alternative embodiment of the enveloped front torso plate;

FIG. 11 is a view of an enveloped side armor plate, shown in partial cut-away, and a carrier jacket, depicting the construction of the enveloped side armor plate and insertion of the side armor plate in the carrier jacket;

FIG. 12 is a partial view in cross section of the enveloped side armor plate shown in FIG. 11, taken at line 12-12;

FIG. 13 is an exploded view of an anti-spalling body armor assemblage in accordance with another aspect of the disclosure;

FIG. 14 is view in elevation of the assembled body shown in FIG. 13, enclosed within an anti-ballistic enclosure; and

FIG. 15 is a perspective view of an alternative assemblage in accordance with a third aspect of the disclosure.

DETAILED DESCRIPTION

FIG. 1 illustrates but one type of protective apparatus that may be worn on a person's or animal's body to protect the wearer from bullet- or small-arms fire. Such protective apparatus are generally structured to cover, in a human, the chest and back area, and the sides or lateral margins of a person's torso. Protective apparatus are commonly known and referred to as bulletproof jackets or flak jackets, or any other number of names or terms, all of which are relevant to the present disclosure. Therefore, reference to or illustration of a single type of protective apparatus is not meant to be limiting of the disclosure. The arrangement of FIG. 1 merely illustrates a simplified form of a protective apparatus that provides ease of illustration of the inventive disclosures herein, and the armor plate arrangements of the anti-spalling body armor system can be adapted to any type, form or configuration of outer carrier device or jacket.

In FIG. 1, a body armor system 10 is shown which is configured for attachment to a wearer's upper torso. In general, the body armor system 10 includes a carrier device 12 which is comprised of a front portion 14, corresponding to the chest area of a wearer, a back portion 16, corresponding to the back area of a person, and side portions 18 that extend between the front portion 14 and the back portion 16 and correspond to the side or lateral areas of a person's torso. In this simple illustration, two shoulder straps 20 are provided to append the carrier device 12 from the wearer's shoulder area. The carrier device 12 is formed with pockets, as will be described further below, into which armor plate elements can be positioned to provide bulletproof and anti-spalling properties to the body armor system 10.

The body armor system 10 of the present disclosure includes a front torso plate 24, shown in phantom in FIG. 1, and shown more specifically in FIGS. 2-4. The front torso plate 24 is sized for positioning over a wearer's chest and has a forward facing surface 26 for orientation away from the wearer's body in use. The front torso plate 24 has an opposing rearward facing surface 28 that is positioned for orientation toward a wearer's body in use.

The front torso plate 24 is configured with a top margin 30 for orientation toward a wearer's head and a bottom margin 32 in opposed position to the top margin 30. Two side margins 34, 36 each extend between the top margin 30 and the bottom margin 32. In a preferred configuration, each of the two side margins 34, 36 comprises an upstanding portion 38 that extends away from the bottom margin 32 and an inwardly directed portion 40 that angles inwardly toward the top margin 30. The configuration provides improved adaptation to the human torso or form.

By way of example, in a particularly suitable configuration, each of the transitional corners C between the top margin 30 and side margins 34, 36, the transitional corners between the bottom margin 32 and side margins 34, 36, and the transitional corners between the upstanding portion 38 and inwardly directed portion 40 of each side margin 34, 36 has a one inch radius R, as shown in FIG. 2.

Further, by way of example, the top margin 30 of the front torso plate 24 is sized in length from between about five inches to about eight inches, as measured between the radius corners C. The bottom margin 32 is sized in length from between about ten inches and about fourteen inches, as measured between the radius corners. The upstanding portion 38 of each side margin 34, 36 is between about seven inches and about ten inches in length, as measured between the radius corners, and the inwardly directed portions 40 of each side margin 34, 36 is between about four inches and six inches, as measured between the radius corners. The angle of the inwardly directed portion 40 is approximately twenty degrees from the upstanding portion 38, and thus approximately seventy degrees from the top margin 30. These measurements are examples only and may vary when adapting the body armor system to wearers of different sizes and shapes.

The front torso plate 24 is further configured with at least three bends or creases to effect a contour of the front torso plate 24 between the two side margins 34 36. As used herein, the term “bend”, when referring to the contoured configuration of the armor elements, is used interchangeably with the term “crease” to describe that the armor elements, including the front torso plate, rear torso plate and side armor plates, are formed in a manner that produces one or more creases in the material which produces a ridge and an angle in the plate that provides a planar region on either side of the crease or bend. The bend or bends effect an overall curvature in the plate.

The front torso plate 24 is configured with at least three bends, or creases, including a medial bend 44 which extends upwardly from the bottom margin 32 toward the top margin 30 of the front torso plate 24, and two lateral bends 46, one each positioned on either side of the medial bend 44. Each lateral bend 46 extends upwardly from the bottom margin 32 of the front torso plate 24.

In one particularly suitable embodiment, the medial bend 44 is aligned along a centerline 50 of the front torso plate 24 and extends upwardly from the bottom margin 32 a distance of between about six inches and about eight inches. The medial bend 44 is formed to provide an angle Y, as shown in FIG. 4, which is between about 160 degrees and about 170 degrees relative to a plane extending along the rearward facing surface 28 on either side of the medial bend 44.

The lateral bend 46 or crease that is formed on either side of the medial bend 44 extends upwardly from the bottom margin 32 a distance of between about five inches and seven inches. Each lateral bend 46 is formed from between one and one half inches to about two and one half inches inwardly from the side margin 34, 36. The lateral bend 46 on either side of the medial bend 44 is formed at an angle X of between about 160 degrees and about 175 degrees relative to a plane extending along the rearward facing surface 28 on either side of the lateral bend 46. Each side marginal panel 52 thus formed by the lateral bends 46 are positioned from between about twenty degrees to about twenty-five degrees relative to a plane P. Additional bends or creases may be formed in the front torso plate 24 to provide more customized curvature of the front torso plate 24 and to improve or adapt the anti-spalling properties. Configuring the front torso plate 24 with creases or bends produces flat planes on either side of the creases or bends that are advantageous in deflecting bullets and bullet fragments, and in providing improved anti-spalling properties to the body armor system 10.

FIG. 5 illustrates an alternative embodiment of a front torso plate 60 having a bottom margin 32 and side margins 34, 36 as previously described, along with having at least three bends or creases as previously described. In this alternative embodiment, the top margin 62 is configured with a flange portion 64 that is angled outwardly in a direction away from the forward facing surface 26. The angle B at which the flange portion 64 is angled, relative to the forward facing surface 28, is between thirty degrees and thirty-five degrees. The flange portion 64 may extend outwardly about one inch from the forward facing surface 28. The flange portion enhances wearability and improves the effectiveness of the body armor system 10. In particular, by providing a flange portion, bullet impact is directed to the muscular portion of the wearer's chest or back area, thereby relieving uncomfortable pressure in the area of the collar bone or neck.

To this point, a description has been provided for a front torso plate 24 of the body armor system 10. The body armor system 10, preferably, includes a rear torso plate that is sized for positioning over a wearer's back in use. The rear torso plate is in every aspect configured in the same manner as previously described for the front torso plate 24. Hence, a rear torso plate 70, in accordance with the disclosure, has an outward facing surface for orientation away from the wearer's body, a top margin for orientation toward a wearer's head, a bottom margin in opposed position to the top margin and two side margins each extending between the top margin and the bottom margin of the rear torso plate. The dimensions of the rear torso plate 70 are those as previously described for the front torso plate 24, including the positioning and configuration of the at least three bends. A rear torso plate may even be configured as shown in FIG. 5 with a top margin that extends away from the rear facing surface of the rear torso plate to provide a flange portion. Thus, it is to be understood that the drawings of FIGS. 2-5 depict not only the front torso plate 24 configuration, but also the rear torso plate 70 configuration.

It is also noted that while the foregoing illustration of FIG. 8 depicts a body armor system 10 with a front torso plate 24 that is configured as shown in FIGS. 2 and 3, the body armor system 10 may equally be comprised of a front torso plate 60 and/or rear torso plate 70 as depicted in FIG. 5.

The body armor system 10 further includes at least two side armor plates 74, as shown in FIGS. 6 and 7, each side armor plate 74 being sized for orientation along one of the two sides of the wearer's body, in use, and being oriented for positioning on either side of the front torso plate 24. In the body armor system 10, the side armor plates are each positioned between the front torso plate 24 and the rear torso plate 70 along the sides of the wearer.

Each side armor plate 74 is formed of a single piece of material, generally having the dimensions of about five inches by six inches, although different sizes are also useful. In particular, the side armor plate may be formed with a greater height relative to its width in order to extend a greater distance along a wearer's side. For example, the side armor plate 74 may have the dimensions of as much as nine inches by six inches. Each side armor plate 74 is formed with at least one bend 76 to provide a contoured shape of the side armor plates 74 for enabling each side armor plate 74 to curve along the sides of the wearer's body. As shown, the at least one bend 76 may be formed along a centerline 78 of the side armor plate 74. However, the at least one bend 76, or plurality of bends or creases, may be formed at other that the centerline of the side armor plate 74.

Each side armor plate 74 is formed with an outwardly facing surface 80 that is positioned, in use, for orientation away from the wearer's body and an inwardly facing surface 82 that is positioned, in use, for orientation toward the user's body. The at least one bend 76 is formed to provide an angle Z of between about 155 degrees to about 165 degrees relative to a plane extending along the inwardly facing surface 82 on either side of the bend 76.

The front torso plate, rear torso plate and side armor plates are preferably made of steel plate, and particularly steel material bearing the nomenclature MIL-A-46100, which is used as armor by the military for light armor vehicle protection. The steel plate is generally about 0.25 inches in thickness, but may be of greater thickness. The steel plate is chosen to maximize ballistic protection against various ammunition types, including for example 7.62-mm, M1943 ball rounds and AK47 rounds. Other bullet resistant plate material, including metal materials such as AR500, can be used as long as it meets or exceeds all aspects of MIL-A-46100 specifications. The metal plates are formed with bends or creases, as described herein, preferably using a cold press process.

Further in accordance with the present disclosure, the front torso plate, the rear torso plate and each side armor plate are each encased within a ballistic impact enclosure to enhance the anti-spalling properties of the body armor system 10. This arrangement is shown in FIGS. 8-12. Referring first to FIG. 8, a front torso plate 24 in accordance with the disclosure is illustrated in readiness for insertion into a carrier device 12 having a pocket 86 that is sealably closed by some means, such as hook and loop fastener material 88.

The front torso plate 24 is positioned within and enclosed by a ballistic impact enclosure 90 that surrounds and envelops the front torso plate 24. The ballistic impact enclosure 90 is generally constructed as a sack or bag and is sized and shaped to receive the armor plate (i.e., front torso plate or rear torso plate) therewithin. The edges of the bag or sack are sewn together or otherwise joined to completely and securely enclose the plate. Alternatively, the sack or bag of the ballistic impact enclosure 90 may be formed with a sealable pocket that allows the plate inside to be removed.

The ballistic impact enclosure 90 is made of a bullet resistant material, such as Kevlar, graphene or similar material. The ballistic impact enclosure 90 may be made of a single layer of bullet resistant material or a plurality of layers of bullet resistant material. A spacing body 92 is positioned against the forward facing surface 28 of the front torso plate 24, the forward facing surface 28 also defining a strike face of the front torso plate 24.

In a first embodiment of the arrangement, shown in FIG. 9, the front torso plate 24 is enclosed in a ballistic impact enclosure 90 comprising a double layer 90A and 90B of bullet resistant material. A spacing body 92 is positioned adjacent to and in registration with the forward facing surface 26, or strike face, of the front torso plate 24. As shown in FIG. 8, the spacing body 92 may be secured to the front torso plate 24 by sections of adhesive tape 96. The spacing body 92 may, alternatively, be adhered to the front torso plate 24 by any number of means, however, including gluing, bonding or spray application. In the embodiment shown in FIG. 9, the spacing body 92 is made of flexible, impact resilient material, such as an elastomeric material or other resilient material, particularly, but not exclusively, synthetic rubber or polymer. In the embodiment of FIG. 9, a space or gap 96 is provided between the spacing body 92 and the ballistic impact enclosure 90, which facilitates anti-spalling properties.

FIG. 10 illustrates an alternative embodiment of the arrangement where the spacing body 92 is affixed to the ballistic impact enclosure 90 rather than being affixed to the forward facing surface 26, or strike face, of the front torso plate 24. Consequently, a space 98 or gap is provided between the spacing body 92 and the strike face of the front torso plate 24.

In either the embodiment of FIG. 9 or FIG. 10, the spacing body 92 is preferably about one quarter inch (0.25 inch) to about one half inch (0.50 inch) in thickness. More than one layer of the spacing body 92 may be used. Either embodiment is effective in providing anti-spalling properties to the body armor system 10. Maintaining the spacing body 92 at 0.25 inch or greater insures that a bullet or bullet fragments encounter the ballistic impact enclosure 90 at a given distance away from the initial impact point, thereby eliminating the possibility of fragmentation exiting the impact point or hole itself. Without a spacing body 92 of adequate thickness, fragmentation could occur with shrapnel radiating on the outside of the ballistic impact enclosure 90 causing injury to the wearer. Reducing fragmentation energy by directing fragments through the spacing body 92 and then capturing fragmentation between the inside of the ballistic impact enclosure 90 and the plate reduces the possibility of injury to the wearer.

While the foregoing discussion has described the enclosure of the front torso plate 24 in a ballistic impact enclosure 90 with a spacing body 92 being provided, it is to be understood that the same description applies equally to the arrangement of a rear torso plate in a ballistic impact enclosure 90 with a spacing body 92 being provided, which is then inserted into a pocket formed in the back portion 16 of a carrier vest 12. Indeed, if a bullet strikes the front torso plate or front portion 14 of the carrier vest 12 and damage occurs, the carrier vest 12 can, in certain configurations, be rotated to place the rear torso plate toward the wearer's front since the front torso plate and rear torso plate are essentially interchangeable and provide equivalent protection.

FIG. 11 further illustrates the assembly, in part, of a body armor system 10 in accordance with the disclosure where one of the side armor plates 74 is positioned for insertion in a carrier vest 12 that has a side portion 18 with a pocket 100, which is configured for being sealed in a closed condition by some means, such as hook and loop fasteners 102. As described with respect to the front torso plate 24, each side armor plate 74 is, in accordance with the disclosure, enclosed within a ballistic impact enclosure 106 that is generally constructed as a sack or bag and is sized and shaped to receive the side armor plate 74 therein. The edges of the bag or sack are sewn together or otherwise joined together to completely and securely enclose the side armor plate 74. The bag or sack may, alternatively, be configured with a sealable pocket sized to receive the side armor plate therein.

The ballistic impact enclosure 106 is made of a bullet resistant material, such as Kevlar, graphene or similar material. As previously described, the ballistic impact enclosure 106 may be made of a single layer of bullet resistant material or a plurality of layers of bullet resistant material. A spacing body 108 is positioned adjacent the outwardly facing surface 80 of the side armor plate 74, the outwardly facing surface 80 also defining a strike face of the side armor plate 74. The spacing body 108 may be secured to the outwardly facing surface 80 of the side armor plate 74 with segments of adhesive tape 110, as previously described. Alternatively, a spacing body 108 may be applied by other means, including gluing, bonding, spray application, or the like.

FIG. 12 illustrates one embodiment of the arrangement of the enveloped side armor plate 74, spacing body 108 and ballistic impact enclosure 106 where the spacing body 108 is adhered to the outwardly facing surface 80 of the side armor plate 74. The ballistic impact enclosure 106, which is illustrated as comprising two layers 106A, 106B of material, surrounds the side armor plate 74 and spacing body 108, leaving a space or gap 114 between the spacing body 108 and the ballistic impact enclosure 106, as previously described. An alternative arrangement, as described with respect to FIG. 10, may be equally adapted to the configuration of the side armor plate 74. Further, while only one side armor plate 74 arrangement is shown in FIG. 11, it is to be understood that a side armor plate 74 arrangement, enclosed within a ballistic impact enclosure 106 as described, would be positionable on the other side of the wearer's body in use.

In accordance with the disclosure, a ballistic protection device for use in a body armor device 10, vest or jacket that is configured for being worn on a body includes a plate 24, 74, made of ballistic metal material, the plate 24, 74 having a surface defining a strike surface 28, 80 for orientation away from a wearer's body in use, and being contoured by the formation of at least one bend in the plate, the plate being surrounded by an enclosure 90, 106 encasing the plate, with the enclosure being made of material having antiballistic capabilities, and including a spacing body 92, 108 positioned between the plate and the enclosure, at least along the strike surface of the plate.

The embodiment of the body armor system 10 described and illustrated in FIGS. 1-12 is effective in reducing or eliminating spalling of bullets that are of a non-spire point type (i.e., those used in handguns). A bullet striking the body armor system 10 strikes the carrier vest, compressing the vest material, and in turn the ballistic impact enclosure, and then the spacing body positioned against the steel armor plate. Non-spire bullets have sufficient velocity to cause the formation of a hole in the carrier vest, ballistic impact material and, often, the spacing body. However, the striking of the bullet against the plate 24 causes deformation and fragmentation of the bullet because the bullet cannot penetrate the plate. Bullet fragmentation occurs as the energy of the bullet is dispersed. Fragments radiate outwardly from the contact area, parallel to the plate surfaces formed by the bends or creases formed in the plate, through the spacing body at approximately ninety degrees from the impact angle and between the plate and the ballistic impact enclosure inside surface.

The fragments are slowed by the spacing body material and, due to the planar surfaces of the bent steel plate, the fragments will encounter the inside surface of the ballistic impact enclosure at a slight angle as they radiate outward. The ballistic impact enclosure captures the fragments, prohibiting them from exiting the vest and causing secondary injury to the wearer. The spacing body, having a selected thickness, insures the bullet fragments encounter the ballistic impact enclosure at a given distance away from the initial impact hole on the carrier vest caused by the bullet, thereby eliminating the possibility of fragmentation exiting the impact hole itself. Without adequate spacing body material, fragmentation could occur with shrapnel radiating on the outside of the ballistic impact enclosure causing injury to the wearer. Reducing fragmentation energy by directing fragments through the spacing body material, and then capturing fragmentation between the inside of the ballistic impact enclosure and the plate, reduces the possibility of injury.

FIG. 13 illustrates another embodiment and aspect of the present disclosure in which a body armor assemblage 200 is configured for providing anti-spalling protection from non-spire point and spire point (i.e., used in handguns and light small arms) ammunition. Spire point ammunition have higher velocity, which results in more aggressive impacts against body armor devices and, therefore, are more likely to result in spalling and bodily injury with conventional devices. AR 15 and equivalent arms, having .223 caliber bullets, are particularly lethal due to the inability of conventional anti-ballistic jackets and vests to withstand the impact of such bullets.

The body armor assemblage 200 of FIG. 13 is especially directed to withstanding impact from higher velocity ammunition. The anti-spalling body armor assemblage 20 includes at least one steel plate 202, configured with a top margin 204, a bottom margin 206 and side margins 208, 210 extending between the top margin 204 and the bottom margin 206, and having an outwardly facing surface 212 oriented, in use, away from a wearer's body. The outwardly facing surface 212 defines a strike face 214. The steel plate is preferably made of military ballistic material, such as MIL-A-46100 or an equivalent material, and is preferably at least 0.25 inches in thickness.

A spacing body 216 is positioned adjacent the strike face 214 of the at least one steel plate 202. The spacing body 216 may be made of a resilient material, such as synthetic rubber or polymer, and it preferably 0.25 inches in thickness or greater. In some embodiments, a plurality of spacing body 216 layers may be employed.

An anti-spalling body 220 is positioned adjacent the spacing body 216. The anti-spalling body 220 is made of a material having anti-ballistic properties, such as Kevlar or an equivalent material. A particularly suitable anti-spalling body 220 is comprised of multiple layers of four ounce Kevlar. The number of layers may be from two to twelve in number, and particularly one to three layers. Alternatively, the anti-spalling body 220 may be comprised of between two and four layers of twelve ounce Kevlar. Alternatively, the layers of the anti-spalling body 220 may be comprised of both four ounce and twelve ounce Kevlar, or equivalent material.

The at least one steel plate 202, spacing body 216 and anti-spalling body 220 are preferably joined together by such means as taping, gluing, bonding, or equivalent means. The assemblage of the at least one steel plate 202, spacing body 216 and anti-spalling body 220 are then positioned within a metal encasement 224 having a covering surface 226 and an upstanding, continuous side 228 that extends outwardly from the covering surface 226. The continuous side 228 is of a depth D sufficient to receive the assemblage of the at least one steel plate 202, spacing body 216 and anti-spalling body 220 within the metal encasement 224. The inner perimeter 230 of the metal encasement 224 is configured and dimensioned to be the same, but slightly greater than, the configuration and dimension of the outer perimeter 232 of the at least one steel plate 202 so that the at least one steel plate 202 fits within the inner perimeter 230 of the metal encasement 224, with a slight gap remaining. The metal encasement 224 is then secured to the at least one steel plate by such means as welding, adhesive, riveting or insertion of bolts or screws. Welding may be a preferred form of joinder. The metal encasement 224 may be made of mild steel, such as twelve gauge steel, or may be made of hardened steel.

As shown in FIG. 14, the assemblage of the at least one steel plate 202, spacing body 216, anti-spalling body 220 and metal encasement 224 are then positioned within an outer ballistic impact enclosure 240, which may be formed as an envelope having an openable end 242, secured by hook and loop material or other means for opening the end 242 to access the assemblage within. The assemblage enclosed within the outer ballistic impact enclosure 240 is then ready for placement within the pocket of a carrier vest or jacket, as previously described.

FIG. 15 illustrates an alternative embodiment of the anti-spalling body armor which is comprised of all of the elements shown in FIGS. 13 and 14, but differs in having the at least one steel plate 250 being configured with a flange portion 252 extending outwardly from the top margin of the plate 250, as previously described. Also, the at least one steel plate 250 may be formed with one or more bends or creases 254 as previously described. In this embodiment, it is understood that the metal encasement that fits over the at least one steel plate 250 and accompanying spacing body and anti-spalling body is similarly formed with bends or creases to provide an assemblage that is contoured to more comfortably fit the torso of the wearer.

The anti-spalling body armor assemblage of FIGS. 13-15 is particularly effective in preventing spalling of bullets, especially spire point bullets, because of its construction. A bullet striking the carrier vest or jacket will produce a hole in the material. The bullet then passes through and hits the ballistic impact enclosure 240 which, with higher velocity bullets, will slow the progress of the bullet, but will still develop a hole. The bullet then encounters the metal encasement 224, which further dissipates the shock wave and begins to deform the bullet. The bullet's encounter with the anti-spalling body 220 and spacing body 216 further dissipate the shock wave, but the high velocity of the bullet typically results in the formation of a hole through the anti-spalling body 220 and spacing body 216. A final strike of the bullet against the steel plate 202 stops the bullet and causes further deformation or fragmentation of the bullet. The arrangement of the assemblage has the advantage over conventional body armor systems in dissipating the shock wave of the bullet such that fragmentation of the bullet upon entry through the assemblage is captured between the steel plate 202 and the anti-spalling body 220, and no fragments are directed outwardly which can cause damage. Consequently, bullet fragments are not directed to the head or other areas of the wearer's body.

In the foregoing description of certain embodiments, specific terminology has been employed for the sake of clarity. However, the disclosure is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes other technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as “left” and right“, “front” and “rear”, “above” and “below” and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms. Indeed, the embodiments and aspects of the disclosure, though described with respect to a device for human use, can also be adapted for use with dogs and other military service animals.

In this specification, the word “comprising” is to be understood in its “open” sense, that is, in the sense of “including”, and thus not limited to its “closed” sense, that is the sense of “consisting only of”. A corresponding meaning is to be attributed to the corresponding words “comprise”, “comprised” and “comprises” where they appear.

In addition, the foregoing describes only some embodiments of the inventions, and alterations, modifications, additions and/or changes can be made thereto without departing from the scope and spirit of the disclosed embodiments, the embodiments being illustrative and not restrictive.

Furthermore, inventions have been described in connection with what are presently considered to be the most practical and preferred embodiments, it is to be understood that the inventions are not to be limited to the disclosed embodiments, but on the contrary, are intended to cover various modifications and equivalent arrangements included within the spirit and scope of the inventions. Also, the various embodiments described above may be implemented in conjunction with other embodiments, e.g., aspects of one embodiment may be combined with aspects of another embodiment to realize yet other embodiments. Further, each independent feature or component of any given assembly may constitute an additional embodiment. 

What is claimed is:
 1. A body armor system for attachment to a wearer's upper torso, comprising a front torso plate sized for positioning over a wearer's chest, the front torso plate having a forward facing surface for orientation away from the wearer's body, a top margin for orientation toward a wearer's head, a bottom margin in opposed position to the top margin and two side margins each extending between the top margin and the bottom margin, the front torso plate being configured with at least three bends to effect a contour of the front torso plate between the two side margins.
 2. The body armor system of claim 1, wherein the at least three bends further comprise a medial bend of the front torso plate, which extends upwardly from the bottom margin toward the top margin of the front torso plate, and two lateral bends, one each positioned on either side of the medial bend, each lateral bend extending upwardly from the bottom margin of the front torso plate.
 3. The body armor system of claim 2, wherein the top margin of the front torso plate is angled outwardly in a direction away from the forward facing surface.
 4. The body armor system of claim 1, wherein the top margin of the front torso plate is angled outwardly in a direction away from the forward facing surface.
 5. The body armor system of claim 1, further comprising at least two side armor plates, each side armor plate being sized for orientation along one of the two sides of the wearer's body and being oriented for positioning on either side of the front torso plate.
 6. The body armor system of claim 5, wherein each of the two side armor plates is formed with at least one bend to provide a contoured shape of the side armor plates for enabling each side armor plate to curve along the sides of the wearer's body.
 7. The body armor system of claim 1, further comprising a rear torso plate sized for positioning over a wearer's back, the rear torso plate having an outward facing surface for orientation away from the wearer's body, a top margin for orientation toward a wearer's head, a bottom margin in opposed position to the top margin and two side margins each extending between the top margin and the bottom margin.
 8. The body armor system of claim 7, wherein the rear torso plate is further configured with at least three bends to effect a contour of the rear torso plate between the two side margins of the rear torso plate.
 9. The body armor system of claim 8, wherein the at least three bends further comprise a medial bend of the rear torso plate, which extends upwardly from the bottom margin toward the top margin of the rear torso plate, and two lateral bends, one each positioned on either side of the medial bend, each lateral bend extending upwardly from the bottom margin of the rear torso plate.
 10. The body armor system of claim 9, wherein the top margin of the rear torso plate is angled outwardly in a direction away from the outward facing surface of the rear torso plate.
 11. The body armor system of claim 8, further comprising two side armor plates, each positioned between the front torso plate and the rear torso plate and being oriented to be positioned along the sides of the wearer's body in use, each side armor plate being contoured to enable each side armor plate to curve about a side of the wearer's body.
 12. The body armor system of claim 11, wherein the front torso plate, the rear torso plate and each side armor plate is each encased within a ballistic impact enclosure and each has a spacing body positioned between at least part of the plate and the ballistic impact enclosure.
 13. The body armor system of claim 12, wherein each of the front torso plate, rear torso plate and two side armor plates is formed with a strike face comprising a surface of the plate that is positioned for orientation away from a wearer's body, and the spacing body is positioned between the strike face of the said front torso plate, rear torso plate and side armor plates and the ballistic impact enclosure.
 14. The body armor system of claim 13, wherein each of the front torso plate, rear torso plate and two side armor plates, encased in the ballistic impact enclosure, is further positioned within a receiving pocket of an outer carrier vest or jacket that is configured for attachment to the upper torso of a wearer.
 15. The body armor system of claim 14, wherein the front torso plate, rear torso plate and two side armor plates is each made of military ballistic steel.
 16. The body armor system of claim 14, wherein the ballistic impact enclosures are made of material having antiballistic property.
 17. The body armor system of claim 14, wherein the spacing body is made of flexible, impact resilient material.
 18. An anti-spalling body armor device, comprising: at least one steel plate having a top margin, a bottom margin and side margins extending between the top margin and the bottom margin, and having an outwardly facing surface oriented, in use, away from a wearer's body, the outwardly facing surface defining a strike face; a spacing body positioned adjacent the strike face of the at least one steel plate; an anti-spalling body positioned adjacent the spacing body; and a metal encasement positioned to encase the spacing body and the anti-spalling body against the at least one steel plate, the metal encasement being secured to the at least one steel plate in sealing arrangement therewithin.
 19. The anti-spalling body armor of claim 18, further comprising an anti-ballistic enclosure sized to receive and enclose the assemblage of the at least one steel plate, spacing body, anti-spalling body and metal encasement therein.
 20. The anti-spalling body armor of claim 18, wherein the anti-spalling body comprises a plurality of layers of woven material having anti-ballistic properties.
 21. The anti-spalling body armor of claim 18, wherein the at least one steel plate further comprises a flange portion positioned along the top margin, the flange portion extending outwardly from the outwardly facing surface.
 22. The anti-spalling body armor of claim 18, further comprising a carrier vest having at a pocket configured to receive the assemblage of the at least one steel plate, spacing body, anti-spalling body and metal encasement within.
 23. The anti-spalling body armor of claim 18, wherein the at least one steel plate is formed with at least one bend extending upwardly from the bottom margin toward the top margin. 